Maintenance systems
Planning
Planning Activities
Planning activities generally include the following:
• 1. Strategic systems alliances
• 2. Maintenance strategies
• 3. Maintenance load forecasting
• 4. Maintenance capacity
• 5. Maintenance organization
• 6. Maintenance scheduling.
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1- Strategic systems alliances
• Maintenance departments should have
their own strategic plans that are aligned
with their organizations’ strategic
objectives and managed with maximum
efficiency and effectiveness taking into
consideration the holistic system approach
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2. Maintenance strategies
The following strategies can play an effective role if applied in the right
mix and fashion. The strategies are as follows:
1. Breakdown/corrective maintenance
2. Preventive maintenance
2:1 Time- or use-based preventive maintenance
2:2 Condition-based preventive maintenance
3. Opportunity maintenance
4. Fault finding
5. Design modification
6. Overhaul
7. Replacement
8. Reliability-centered maintenance
9. Total productive maintenance
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Breakdown/Corrective Maintenance
• This type of maintenance is only performed
when the equipment is incapable of further
operation. There is no element of planning for
this type of maintenance. This is the case when
the extra cost of other types of maintenance
cannot be justified. This type of strategy is
sometimes referred to as run to failure strategy.
It is applicable mostly to electronic components.
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Preventive Maintenance
• Preventive maintenance (PM) is any planned maintenance
performed to counteract potential failures.
• Time- or Use-Based Preventive Maintenance
is performed on an hours run or calendar basis. It needs a
high level of planning.
• Condition-Based Preventive Maintenance
is carried out on the basis of the known condition of the
equipment. The condition of the equipment is determined
by monitoring key equipment parameters whose values
are affected by the condition of the equipment. This
strategy is also known as predictive maintenance
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Opportunity Maintenance
• This type of maintenance, as the name
implies, is carried out when the
opportunity arises. Such opportunities may
arise during shutdown periods of a
particular system and can be utilized for
carrying out known maintenance tasks.
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Fault Finding
• Fault finding is an act or inspection
performed to assess the level of failure set
on. An example of fault finding is checking
the spare tire of a car prior to taking a
long trip.
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Design Modification
• Design modification is carried out to bring
equipment to a current acceptable
condition. It involves improvement and
sometimes manufacturing and capacity
expansion. It usually requires coordination
with engineering and other departments in
the organization to do this type of work.
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Overhaul
• Overhaul is a comprehensive examination
and restoration of equipment or a major
of equipment to an acceptable condition.
This is usually a major task.
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Replacement
• This strategy is to replace the equipment
instead of performing maintenance. It
could be a planned replacement or
replacement upon failure.
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Maintenance strategies
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3-Maintenance Load Forecasting
• Maintenance load forecasting is the
process by which the maintenance load is
predicted.
• can be a function of the age of the
equipment, the rate of its use,
maintenance quality, climatic factors, and
skills of maintenance craftsmen.
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The role played by maintenance load forecasting in
a maintenance system
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4- Maintenance Capacity Planning
• Maintenance capacity planning determines
the resources needed to meet the demand
for maintenance work. Those resources
include manpower, material, spare parts,
equipment, and tools.
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5- Maintenance Organization
• Many factors influence maintenance
organization. The factors include plant
size, maintenance load, type of
organization, and craftsmen skills. Based
on these factors and other, maintenance
may be organized on departmental, area,
or central basis.
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Maintenance Organization
Cascade system
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6- Maintenance Scheduling
• Maintenance scheduling is the process of
assigning resources and manpower to jobs
to be accomplished at certain times. It is
necessary to ensure that the needed
craftsmen, the parts, and the materials
required are available before a
maintenance task can be scheduled.
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